Vertical Hydroponic Plant Production Apparatus

ABSTRACT

A vertical hydroponic plant production apparatus for allowing vertical hydroponic greenhouse crop production is provided. The apparatus comprises a hollow grow tube having a front face, a back face, an open first end, and an open second end. A slot is formed in the front face of the grow tube with the slot having a width equal to only a portion of a width of the front face. A media material is insertable into the grow tube. The slot allows the front face to expand outward during insertion of the media material and biased inward against the media material once the media material is inserted. The grow tube is positionable in either a horizontal position, vertical position, or any position between the horizontal position and the vertical position allowing inclined, multi-angled crop production and multi-storied conveyor style crop production.

The present application is a continuation-in-part of pending U.S. patentapplication Ser. No. 12/804,931, filed on Aug. 2, 2010, entitledVertical Hydroponic Plant Production Apparatus, which claims benefit ofpriority of provisional patent application Ser. No. 61/273,317, filed onAug. 3, 2009, entitled “Vertical Hydroponic Plant Production Apparatus”.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a vertical hydroponic plantproduction apparatus and, more particularly, the invention relates to avertical hydroponic plant production apparatus allowing for verticalhydroponic greenhouse crop production in a fraction of the spacenecessary for traditional plant production techniques and allowingutilization of vertical surfaces for plant production.

2. Description of the Prior Art

Traditional hydroponics has focused primarily on horizontal productiontechniques and has been subject to major space constraints. Verticalhydroponic applications have either been impractical, expensive tooperate, or inefficient. Often these applications utilize some type ofgrowth medium that is heavy when saturated, causing clogging when filledwith plant roots, and/or requiring a great deal of maintenance. Inaddition, conventional technology makes it difficult to allow in-storedisplay of live, growing vegetables and is not conducive to “you-pick”vegetable and herb sales to customers. Little technology exists thatallows vertical plant displays that are highly scalable.

SUMMARY

The present invention is a vertical hydroponic plant productionapparatus for allowing vertical hydroponic greenhouse crop production.The apparatus comprises a hollow grow tube having a front face, a backface, an open first end, and an open second end. A slot is formed in thefront face of the grow tube with the slot having a width equal to only aportion of a width of the front face. A media material is insertableinto the grow tube. The slot allows the front face to expand outwardduring insertion of the media material and biased inward against themedia material once the media material is inserted. The grow tube ispositionable in either a horizontal position, vertical position, or anyposition between the horizontal position and the vertical positionallowing inclined, multi-angled crop production and multi-storiedconveyor style crop production.

In addition, the present invention includes a method for allowingvertical hydroponic greenhouse crop production. The method comprisesproviding a hollow grow tube having a front face, a back face, a firstend, and a second end, forming a slot in the front face of the grow tubewith the slot having a width equal to only a portion of a width of thefront face, inserting a media material into the grow tube, expanding thefront face outward during insertion, biasing the front face inwardagainst the media material, and positioning the grow tube in either ahorizontal position, vertical position, or any position between thehorizontal position and the vertical position allowing inclined,multi-angled crop production and multi-storied conveyor style cropproduction.

The present invention further includes a vertical hydroponic plantproduction apparatus for allowing vertical hydroponic greenhouse cropproduction. The apparatus comprises a hollow grow tube having a frontface, a back face, a first end, and a second end. A slot is formed inthe front face of the grow tube with the slot having a width equal toonly a portion of a width of the front face. A media material isinsertable into the grow tube with the media material being composed oftwo halves of material split down the middle with a bolt spanning thewidth of the two halves for joining the two halves. A pulling hook isprovided having a flat portion for grasping the bolt for inserting andremoving the media material from the grow tube. An “H” bracket having areceiving portion and an anchoring portion, the “H” bracket is mountedto the rear face of the grow tube. A “Z” bracket having a vertical,upward facing tongue portion receivable within the receiving portion ofthe “H” bracket is provided with the “Z” bracket mounted in apredetermined location. An aperture is formed in the “Z” bracket forreceiving a fastening mechanism. The grow tube is positionable in eithera horizontal position, vertical position, or any position between thehorizontal position and the vertical position allowing inclined,multi-angled crop production and multi-storied conveyor style cropproduction. The slot allows the front face to expand outward duringinsertion of the media material and biased inward against the mediamaterial once the media material is inserted. As weight is applied tothe tongue portion of the “Z” bracket through the placement of a growtube, downward torque is applied across the “Z” bracket causing a clutchaction to affix the “Z” bracket tightly to the predetermined location.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view illustrating a grow tube of avertical hydroponic plant production apparatus, constructed inaccordance with the present invention;

FIG. 2 is a rear perspective view illustrating the grow tube of thevertical hydroponic plant production apparatus of FIG. 1, constructed inaccordance with the present invention;

FIG. 3 is a front perspective view illustrating another embodiment ofthe grow tube of the vertical hydroponic plant production apparatus,constructed in accordance with the present invention;

FIG. 4 is a rear perspective view illustrating the grow tube of thevertical hydroponic plant production apparatus of FIG. 3, constructed inaccordance with the present invention;

FIG. 5 is a front perspective view illustrating a media column of thevertical hydroponic plant production apparatus, constructed inaccordance with the present invention;

FIG. 6 is a rear perspective view illustrating the media column of thevertical hydroponic plant production apparatus of FIG. 5, constructed inaccordance with the present invention;

FIG. 7 is a perspective view illustrating a Z bracket of the verticalhydroponic plant production apparatus, constructed in accordance withthe present invention;

FIG. 8 is a perspective view illustrating a pulling hook of the verticalhydroponic plant production apparatus, constructed in accordance withthe present invention;

FIG. 9 is a perspective view illustrating the vertical hydroponic plantproduction apparatus, constructed in accordance with the presentinvention, with the slot formed to a point below the first end of thegrow tube;

FIGS. 10-12 is a perspective view illustrating the vertical hydroponicplant production apparatus, constructed in accordance with the presentinvention, with the media material being composed of two halves ofmaterial split down the middle with a bolt spanning the width of the twohalves;

FIG. 13 is a perspective view illustrating the vertical hydroponic plantproduction apparatus, constructed in accordance with the presentinvention, with the media material having a thickness substantially halfan internal width/diameter of the grow tube such that the media materialis folded in the middle so that the thickness both halves togetherroughly equal the inside dimensions of the grow tube;

FIG. 14 is a perspective view illustrating the vertical hydroponic plantproduction apparatus, constructed in accordance with the presentinvention, with a cap and tubing extending through the cap;

FIG. 15 is a perspective view illustrating the vertical hydroponic plantproduction apparatus, constructed in accordance with the presentinvention, with a nutrient solution reservoir; and

FIG. 16 is a perspective view illustrating the vertical hydroponic plantproduction apparatus, constructed in accordance with the presentinvention, with a pump.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in FIGS. 1-16, the present invention is a verticalhydroponic plant production apparatus, indicated generally at 10,allowing vertical hydroponic greenhouse crop production in a fraction ofthe space necessary for traditional plant production techniques andallows utilization of vertical surfaces for plant production.

The vertical hydroponic plant production apparatus 10 of the presentinvention includes a grow tube 12 useable in a horizontal position,vertical position, or any position between the horizontal position andthe vertical position. The grow tube 12 is highly portable, being light,making it easy to move the grow tube 12 from area to area fortransplant, grow out, and harvest. The grow tube 12 further allowsinclined, multi-angled crop production and multi-storied conveyor stylecrop production. The grow tube 12 of the vertical hydroponic plantproduction apparatus 10 of the present invention also functions asaquacultural biofiltration/nutrient stripping devices for plant-based,high-efficiency waste nutrient removal and as sites nitrificationprocesses, having massive surface area/volume thereby reducing the costsof single pass aquaculture and improving the efficiency of recirculatingaquaculture.

The grow tube or tower 12 of the vertical hydroponic plant productionapparatus 10 of the present invention also functions as in-store or atmarket display devices allowing the display of fresh, live produce foryou-pick vegetable sales at market places and allowing the sale ofproduce that is more fresh than traditionally harvested vegetableproducts. Designed for easy affixation to the walls and/or roofs ofbuildings, the grow tube 12 reduces heating and cooling costs throughshading and plant evapotranspiration and performs a decorative function.The grow tube 12 applied in such a manner can also reduce rooftop andhard surface water runoff depending on application and plumbing system.

Basically, the vertical hydroponic plant production apparatus 10 of thepresent invention allows for decorative landscape designs as well asvertical plant production displays indoors for a variety of purposes.The grow tubes or towers 12 can house aromatic and decorative species ofherbs that may be used for aromatherapy type interactive hallways, lobbydisplays, kitchen, and cafeteria displays as well as common industrialplant displays in offices and workspaces.

The grow tube 12 of the vertical hydroponic plant production apparatus10 of the present invention has a first end 14 and a second end 16 andis preferably a square, triangular, or angular tubing containing anon-woven matrix media 18 composed of any number of plastic materials,suspended vertically from the ceiling, supported by a framework, and/orstanding upright on the floor using a support pole or frame. Preferably,the grow tube 12 is constructed of a PVC plastic material with sidewalls having a width of approximately four (4″) inches to six (6″)inches although constructing the grow tube from a different materialwith different widths is within the scope of the present invention.

The grow tube 12 of the vertical hydroponic plant production apparatus10 of the present invention has a slot 20 formed lengthwise through thegrow tube 12. The slot 20 can be formed along the entire face of thegrow tube 12 from the first end 14 to the second end 16 or the slot 20can be formed to a point approximately four (4″) inches to approximatelysix (6″) inches from the first end 14 of the grow tube 12. In the caseof the slot 20 formed along the entire face of the grow tube 12, theslot 20 can have angled portions 22 at the first end 14 of the grow tube12 allowing for easy insertion and removal of the media, as will bedescribed further below. Preferably, the slot 20 has a width ofapproximately one-half (½″) inch to approximately one and one-half (1½″)inches although constructing the slot 20 with different widths is withinthe scope of the present invention.

As mentioned briefly above, the vertical hydroponic plant productionapparatus 10 of the present invention has a media material 18 preferablyconstructed from a polyester matrix material approximately two (2″)inches thick, cut to the internal width/diameter of the grow tube, andfolded in the middle so that both halves together roughly equal theinside dimensions of the grow tube or tower housing 12. The mediamaterial 18 can also be composed of two halves of approximately two (2″)inch thick media or one piece of four (4″) inch thick media split downthe middle to within approximately four (4″) inches to approximately six(6″) inches of the top of the media material where a bolt spans itswidth. In the bolt embodiment of the present invention, this bolt notonly spans the width of the media insert 18, joining the two halves,and/or lending structural integrity to the media insert, but alsoanchors a handle or receiver to the media 18, allowing either the handleto be grasped for the purposes of inserting and removing the media 18insert from the grow tube 12, or allowing a forked or hooked handle tobe inserted into the receiver for the same purpose.

In the embodiment of the vertical hydroponic plant production apparatus10 of the present invention where the media material 18 is folded inhalf, a pulling hook 24 with a flat hook 26 attached to a handle 28allows the media inserts 18 to be pulled into and out of the grow tube12, with the pulling hook handle 28 extending from the slot 20 in thegrow tube 12. The hook 24 preferably consists of a piece of round barmetal bent to form a broad, flat, “L” shaped hook, roughly the width ofthe folded media 18 with a handle 28 affixed to the end. The hook 26 canalso be attached to a pneumatic or hydraulic device that allowsautomated “pulling” of the media inserts 18.

For planting, seedlings are placed between the two halves of media 18 ofthe vertical hydroponic plant production apparatus 10 of the presentinvention, with the upper portions out, and are “zipped” into the growtubes 12 with the upper portions of the plant protruding through the gapin the tower housing 12. The top of the grow tube 12 can be capped witha removable cap having holes of variable sizes drilled in the center, ormay not be capped at all. If capped, a mister or irrigation tubing isinserted through the hole in the cap hole. The bottom of the grow tube12 is either submerged in nutrient solution, rests in a drain or troughfor recirculating nutrient solution, or fits into a lower pipe. A pumpmoves nutrient solution from a nutrient solution reservoir to the misteror irrigation pipe at the top of the grow tube 12, where the nutrientsolution is emitted and allowed to drip down through the media 18 andplant roots. Some of the nutrient solution trickles down the walls ofthe pipe 12 and is captured by roots in contact with the pipe wall.Excess nutrient solution drains to the bottom of the pipe 12 where it isdrained back to the nutrient solution reservoir. High humidity ismaintained within the grow tube due to the constant trickling/misting ofnutrient solution. The height of the plant grow tube 12 is variabledependent on greenhouse height, and the spacing for plants is variabledependent on plant type and desired spacing. It is possible to stackgrow tubes 12 on top of each other to vary height, by fitting thebottoms of the grow tubes 12 with coupling caps, to utilize conveyorproduction techniques.

The grow tubes 12 of the vertical hydroponic plant production apparatus10 of the present invention can be fixed in place using hangers, rope,or strap and metal hooks that loop over a support beam or bracket andsecure to the grow tube 12 or tower through holes 30 drilled at thefirst end of the grow tube 12. The holes 30 can be of variable size andplacement depending on application, although in the most commonembodiment, there are four holes 30, one pair centered on either side ofthe housing upper, and one pair forward (towards the front of the growtube 12) of the centered pair allowing slight inclination of the hangingtower 12 if inclined growing is desired. The grow tubes 12 can also befixed in place using a series of holes or a gap cut in the grow tube 12allowing the grow tube to be fixed to a pole having a bracket orpressure or spring action hanging system attached to it. The grow tube12 can also be inclined on said pole or hanging system for the purposeof inclined production.

The grow tube 12 of the vertical hydroponic plant production apparatus10 of the present invention can also be secured to a support poleutilizing a system of metal brackets whereas one bracket type is femaleand is designated as an “H” bracket 32 and the other bracket type ismale and is designated as a “Z” bracket 34. The female “H” bracket 32has a receiving portion and an anchoring portion to bolt to the back orside of the tower 12. The male “Z” bracket 34 consists of a vertical,upward facing tongue portion that fits into the receiving portion of thefemale bracket 32, and has a hole 36 through the middle, angled portionof the bracket 34 which fits over a support pole. The rear, downwardfacing vertical portion of the bracket 34 has a hole 38 drilled midwayacross the bottom of the bracket 34 and is threaded to receive a bolt.As weight is applied to the tongue portion of the bracket 34 through theplacement of a bracketed tower, downward torque is applied across the“Z” bracket 34 causing a clutch action to affix the bracket tightly tothe support pole. The torque attachment of this “Z” bracket 34 can beenhanced by tightening the bolt threaded into the rear of the bracket 34against the support pole, applying even more pressure for bracketattachment.

The media insert 18 of the vertical hydroponic plant productionapparatus 10 of the present invention can also be altered in severalways to serve a diverse range of functions. The media 18 can be cut at ataper from the unfastened or unfolded end to the fastened or folded end,reserving a tapered space at the rear of the insert to allow compost,alternate plant media, fertilizing substance or some type of soilamendment or additive to be held in the space between the tapered mediainsert and the rear and sidewalls of the tower housing 12. Thisalteration allows compost based hydroponic plant production usingregular irrigation water, with plant nutrients supplied by the compostor other additive. Tops, sides, and corners of the media insert 18 canalso be cut, rounded, or cut at an angle to reduce biosolidsaccumulation, algal growth, or to enhance water distribution through themedia 18, depending on application. Multiple inserts 18 can also be usedin towers 12 allowing multiple age groups of plants to incorporated intoeach grow tube 12. Worms are also commonly integrated into the growtubes 12 and the media is designed to have the correct mesh size toaccommodate their movement through the media 18, although media 18 witha smaller or larger mesh size may be used depending on application.

The vertical hydroponic plant production apparatus 10 of the presentinvention is comparatively lightweight, inexpensive to manufacture(being based on common PVC extrusion techniques) and existingpolyethylene matrix material production, will not clog with nutrientsolution, and requires much less labor to operate. The present inventioncan also be converted to more traditional horizontal productiontechniques if desired, eliminating the risk inherent in changingproduction techniques for commercial producers.

In addition, traditional nitrogen and phosphorus removal techniques inaquaculture are very poor compared to removal using plant uptake forphytoremediation. Plants are able to remove N and P to levels an orderof magnitude lower than any mechanical/chemical/microbial techniquecurrently in use. The present invention phytoremediates water allowingfor prolonged water use/recirculation and water conservation.

The vertical hydroponic plant production apparatus 10 of the presentinvention is an improvement on traditional harvesting and sales modelswhere production systems are physically removed from the sales systemsand shipping and handling results in a large percentage of producerlosses, both financially as wasted or expired produce. By selling liveplants, there is no spoilage and shipping and handling is done partiallyby producers moving towers to market places, but primarily by consumerswho are interested in fresh produce and the experience of picking andharvesting vegetables, herbs and greens for their own use. The growtubes are easily transported and easy to stack, lift, and slide ontoshelves. They essentially operate as a packaging system as well as aplant production system. Further, by utilizing individual towers,landscape designers and home users can scale their display or productionsystem exactly to their specifications.

The vertical hydroponic plant production apparatus 10 of the presentinvention reduces necessary growing space tremendously. Typicalreductions in growing space utilizing a vertical aeroponic techniquehave varied between 60% and 85% compared to conventional growth methods.Greenhouse growing space is very expensive, so the ability to increasecrop size without increasing greenhouse space could prove veryprofitable. The present invention is also very affordable tomanufacture, building on existing PVC pipe production infrastructure.Implementation of the present invention will also be simple, building oncurrent hydroponic production technology.

The increased water recirculation time achieved with the verticalhydroponic plant production apparatus 10 of the present invention caneliminate one of the high costs and reduce the negative environmentaleffects of aquaculture, resulting in increased profits and a betterindustry image for aquacultural producers. Using the present inventioncan also allow aquacultural producers to diversify their product baseand/or grow supplementary feed products (depending on the dietary needsof the fish).

The vertical hydroponic plant production apparatus 10 of the presentinvention has the potential to open up an entirely new system ofproduction, transportation, shipping, handling, and display to vegetableproducers, retailers, and consumers. This can result in fresher produce,a more pleasant customer shopping experience, reduced waste, reducedhandling and packaging costs, fewer food miles, less plastic andpackaging material consumption, and longer shelf life of purchasedproduce.

The vertical hydroponic plant production apparatus 10 of the presentinvention can be used by industrial institutions for phytoremediation ofwaste waters, using the towers as trickling, plant integrated filtersfor the removal of waste materials, and the remediation of waste watersfor discharge.

The foregoing exemplary descriptions and the illustrative preferredembodiments of the present invention have been explained in the drawingsand described in detail, with varying modifications and alternativeembodiments being taught. While the invention has been so shown,described and illustrated, it should be understood by those skilled inthe art that equivalent changes in form and detail may be made thereinwithout departing from the true spirit and scope of the invention, andthat the scope of the present invention is to be limited only to theclaims except as precluded by the prior art. Moreover, the invention asdisclosed herein may be suitably practiced in the absence of thespecific elements which are disclosed herein.

What is claimed is:
 1. A vertical hydroponic plant production apparatusfor allowing vertical hydroponic greenhouse crop production, theapparatus comprising: a hollow grow tube having a front face, a backface, an open first end, and an open second end; a slot formed in thefront face of the grow tube, the slot having a width equal to only aportion of a width of the front face; a media material insertable intothe grow tube; wherein the slot allows the front face to expand outwardduring insertion of the media material and biased inward against themedia material once the media material is inserted; and wherein the growtube is positionable in either a horizontal position, vertical position,or any position between the horizontal position and the verticalposition allowing inclined, multi-angled crop production andmulti-storied conveyor style crop production.
 2. The apparatus of claim1 wherein the grow tube has a shape selected from the group consistingof square, triangular, and angular.
 3. The apparatus of claim 1 whereinthe slot is formed along the entire front face of the grow tube from thefirst end to the second end.
 4. The apparatus of claim 3 wherein theslot has angled portions at the first end of the grow tube.
 5. Theapparatus of claim 1 wherein the slot is formed from the second end to apoint short of the first end.
 6. The apparatus of claim 1 wherein mediamaterial has a thickness substantially half an internal width/diameterof the grow tube such that the media material is folded in the middle sothat thickness of both halves together roughly equal to insidedimensions of the grow tube.
 7. The apparatus of claim 1 wherein themedia material is composed of two halves of material split down themiddle with a bolt spanning a width of the two halves for joining thetwo halves.
 8. The apparatus of claim 7 and further comprising: apulling hook having a flat portion for grasping the bolt for insertingand removing the media material from the grow tube.
 9. The apparatus ofclaim 8 wherein the pulling hook includes a length of material forming abroad, flat, “L” shaped hook with a handle affixed to an end.
 10. Theapparatus of claim 1 and further comprising: a cap positionable over thefirst end of the grow tube; a plurality of holes formed in the cap; anutrient solution reservoir, the second end of the grow tube beingsubmerged in the reservoir; tubing extending from the reservoir throughthe holes; and a pump for pumping nutrient solution from the reservoirinto the grow tube through the tubing.
 11. The apparatus of claim 1 andfurther comprising: holes formed in sides of the first end of grow tubeto hang the grow tube in a desired position from an overhead bar or beamwith a flexible line and wire hooks, or to allow the grow tube/tower tobe mounted on an upright support post.
 12. The apparatus of claim 1 andfurther comprising: a “U” bracket having a receiving portion and ananchoring portion, the “U” bracket mounted to the rear face of the growtube; a “Z” bracket having a vertical, upward facing tongue portionreceivable within the receiving portion of the “U” bracket, the “Z”bracket mounted in a predetermined location; and an aperture formed inthe “Z” bracket for receiving a fastening mechanism; wherein as weightis applied to the tongue portion of the “Z” bracket through theplacement of the grow tube, downward torque is applied across the “Z”bracket causing a clutch action to affix the “Z” bracket tightly to thepredetermined location.
 13. A method for allowing vertical hydroponicgreenhouse crop production, the method comprising: providing a hollowgrow tube having a front face, a back face, a first end, and a secondend; forming a slot in the front face of the grow tube, the slot havinga width equal to only a portion of a width of the front face; insertinga media material into the grow tube; expanding the front face outwardduring insertion; biasing the front face inward against the mediamaterial; and positioning the grow tube in either a horizontal position,vertical position, or any position between the horizontal position andthe vertical position allowing inclined, multi-angled crop productionand multi-storied conveyor style crop production.
 14. A verticalhydroponic plant production apparatus for allowing vertical hydroponicgreenhouse crop production, the apparatus comprising: a hollow grow tubehaving a front face, a back face, a first end, and a second end; a slotformed in the front face of the grow tube the slot having a width equalto only a portion of a width of the front face; a media materialinsertable into the grow tube, the media material being composed of twohalves of material split down the middle with a bolt spanning the widthof the two halves for joining the two halves; a pulling hook having aflat portion for grasping the bolt for inserting and removing the mediamaterial from the grow tube; an “H” bracket having a receiving portionand an anchoring portion, the “H” bracket mounted to the rear face ofthe grow tube; a “Z” bracket having a vertical, upward facing tongueportion receivable within the receiving portion of the “H” bracket, the“Z” bracket mounted in a predetermined location; and an aperture formedin the “Z” bracket for receiving a fastening mechanism; wherein the growtube is positionable in either a horizontal position, vertical position,or any position between the horizontal position and the verticalposition allowing inclined, multi-angled crop production andmulti-storied conveyor style crop production; wherein the slot allowsthe front face to expand outward during insertion of the media materialand biased inward against the media material once the media material isinserted; and wherein as weight is applied to the tongue portion of the“Z” bracket through the placement of a grow tube, downward torque isapplied across the “Z” bracket causing a clutch action to affix the “Z”bracket tightly to the predetermined location.
 15. The apparatus ofclaim 14 wherein the grow tube has a shape selected from the groupconsisting of square, triangular, and angular.
 16. The apparatus ofclaim 14 wherein the slot is formed along the entire front face of thegrow tube from the first end to the second end.
 17. The apparatus ofclaim 16 wherein the slot has angled portions at the first end of thegrow tube.
 18. The apparatus of claim 14 wherein the slot is formed fromthe second end to a point short of the first end.
 19. The apparatus ofclaim 14 wherein the pulling hook includes a length of material forminga broad, flat, “L” shaped hook with a handle affixed to an end.
 20. Theapparatus of claim 14 and further comprising: a cap positionable overthe first end of the grow tube; a plurality of holes formed in the cap;a nutrient solution reservoir, the second end of the grow tube submergedin the reservoir; tubing extending from the reservoir through the holes;and a pump for pumping nutrient solution from the reservoir into thegrow tube through the tubing.